Contact removal bushing for electrical connector

ABSTRACT

An electrical connector having a built-in tool for removing electrical contacts from the connector for maintenance and/or repair. Each of the contacts of the connector includes a movable bushing mounted thereon which is operable to release the contact from the connector insert. The configuration of the contact and movable bushing is such that the movable bushing may be expanded larger than the opening at the end of the bore through which the bushing passed to gain entry to the retention portion of the connector insert.

United States Patent [19] Bright CONTACT REMOVAL BUSHING FOR ELECTRICAL CONNECTOR [75] Inventor: Edward J. Bright, Bainbridge, N.Y.

[73] Assignee: The Bendix Corporation, Southfield,

Mich.

22 Filed: Feb. 27, 1973 21 Appl. No.: 336,306

52 us. Cl 339/217 s, 29/427 51 Int. Cl non 9/08 [58] Field of Search 339/217 s; 285/39, 321;

[56] References Cited FOREIGN PATENTS OR APPLICATIONS 1,515,887 5/1970 Germany 339/217 S [111 3,805,219 Apr. 16, 1974 Primary Examiner-Joseph H. McGlynn Assistant Examiner-Robert A. Hafer Attorney, Agent, or FirmRaymond J. Eifler [57] ABSTRACT An electrical connector having a built-in tool for removing electrical'contacts from the connector for maintenance and/orrepair. Each of the contacts of the connector includes a movable bushing mounted thereon which is operable to release the contact from the connector insert. The configuration of the contact and movable bushing is such that the movable bushing may be expanded larger than the opening at the end of the bore through which the bushing passed to gain entry to the retention portion of the connector insert.

16 Claims, 6 Drawing Figures PATENTEDAPR 151914 I 3,805,219

40- I 1 I Y 45 FIG. 6

CONTACT REMOVAL BUSHING FOR ELECTRICAL CONNECTOR BACKGROUND OF THE INVENTION This invention relates to electrical connectors of the type having contacts that are removably mounted within the insulating body of the insert. This invention is more particularly related to a removable contact and the contact release tool captively mounted therewith.

In U.S. Pat. No. 3,1 10,093 entitled Contact Extraction and Insertion Tool" issued Nov. 12, 1963 to G. S. Johnson, there is disclosed a tubular tool for releasing removable contacts which slips over a wire attached to the contact and is moved axially around the contact to release the contact from a retaining clip. However, such a tool is limited in application to situations in which the tool can be slipped over the wire and there is adequate space between the wire and the bore walls surrounding the contact to permit the tool to be actually moved onto the terminal. Similarly, in US. Pat. No. 3,382,558 entitled Electrical Connector Captivated Rear Release Tool" issued May 14, 1968 to L. H. LUtz, there is disclosed a tubular Lutz, for releasing removable contacts which ispermanently mounted on the electrical contact.

US. Pat. No. 3,221,292 entitled Electrical Connector issued Nov. 30, 196 5 to G. J. Swanson et al. illustrates a multipin electrical connector of the type associated with this invention. One of the problems associated with multipin electrical connectors that have removable contacts is that the contact removal tool and the contact retention assembly associated with retaining the contact affects the contact density, i.e. limits the total number of contacts that may be placed within a given area. Further, contact removal tools that require an air space around the electrical contact decreases the amount of dielectric insulation between contacts and therefore lowers the breakover voltage, something which is most undesirable. A further important limitation on prior art contact removal tools is that the forward portion of the tool that is designed to release the contact retention mechanism is not larger than the opening in the insert that receives the tool and in all known instances the forward portion of the tool that releases the contact retaining mechanism was not radially expandable to an area greater than the opening in the contact insert that received the tool. The disadvantage with this limitation is that in some instances, the tool, (because of wear, poor design or because of mixed tolerances between the contact and tool) did not deflect the contact retention member to release the contact so that the contact could be withdrawn from the connector insert.

SUMMARY OF THE INVENTION mounted on an electrical contact is further characterized by the fact that the end portion (46) that is within the bore of the insert (10) cooperates with an enlarged portion (32) of the contact (30) to open to a diameter larger than the entrance opening (13) that originally received the end portion (46) of the bushing (40).

In one embodiment of the invention, the invention may be described as an apparatus for releasing a removable electrical contact pin (30) from a bore in a connector insert (10), the pin (30) having a first enlarged section (31) forming a first shoulder (310) and a second enlarged section (32) adjacent said first shoulder'(3l the contact pin (30) secured in the bore by a radially deflectable and inwardly extending retention member (21) that engages the first shoulder (310) facing in the direction of said second enlarged section (32), the remaining portion (36) of the contact (30) that extends from said second enlarged portion (32) in the direction away from said first shoulder (310) is spaced from the surrounding walls of the bore, the second enlarged section (32) further including a tapered portion (320) which tapers radially inwardly in a direction away from the first shoulder (31); and a bushing (40) having a resiliently expandable end portion (46), the bushing is slideably mounted on the contact portion (36) that extends into the bore for axial movement of said expandable end portion (46) into the bore, so that when the bushing (40) is forced over the second enlarged portion (32) of the contact (30), the bushing expands radially against the deflectable retention member (21) whereby the. inwardly extending retention member is radially deflected and disengaged from the contact first shoulder (31) so that the contact may be withdrawn from the bore-in the connector. In the preferred embodiment of the invention, the bushing (40) includes an axial slot (41) that extends the entire length of the bushing, making the bushing expandable.

Accordingly, it is an object of this invention to provide a contact removal tool that is part of the connector assembly and which is radially expandable within the insert bore to disengage one or more retention members that retain the electrical contact within the connector.

It is another object of this invention to provide a removable bushing and contact assembly that cooperates in a manner that pennits the removable bushing to be enlarged to an extent greater than the opening in the insert through which the expandable portion has passed.

It is also an object of this invention to provide a tool for removing electrical contacts from a multipin electrical connector.

It is a further object of this invention to provide an electrical connector having an improved low cost, captivated tool for removing electrical contacts from an insulation body in the connector.

It is still a further object of this invention to minimize the diameter of a bore required to receive a removable contact and the removable tool associated therewith.

The above and other objects and features of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings and claims which form a part of this specification.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional view of the captivated tool DETAILED DESCRIPTION OF THE DRAWINGS Referring now to the drawings, FIG. 1 illustrates one embodiment of the invention used in combination with an electrical connector that includes a dielectric insert a contact retaining mechanism (20), an electrical contact (30), and a captivated removal bushing (40).

The dielectric insert (10) includes a bore that terminates in an opening (13) at a first face (11) of the insert (10).

Disposed within the passage of the insert (10) is a retention mechanism (20) which generally includes one or more radially deflectable fingers or members (21) that extend inwardly with respect to the axis of said insert bore. Another example of a retention mechanism may be found in U.S. Pat. No. 3,165,369 entitled Retention System for Electrical Contacts issued .Ian. 12, 1965 to J. W. Maston. The deflectable retention members (21) cooperate with a shoulder (310) on the contact (30) to prevent movement of said contact in the direction of said first face. The passage in the insert further includes means for stopping the movement of a contact (30) in the direction away from the first face (11) at a predetermined point. In this embodiment the stop means comprises an internal shoulder that engages a shoulder (311) of the contact (30) to prevent further movement of the contact (30) in a direction away from said first face (11).

The electrical contact (30) includes a first enlarged portion (31), a second enlarged portion (32) and a remaining portion (36) that extends from said second enlarged portion (32) to one end of the contact. The enlarged portion (31) of said contact (30) includes a first shoulder (310) facing in the direction of the insert first face (11) and a second shoulder (311) that faces in the I direction away from the insert first face 11). The first shoulder (310) is adapted to engage the radially deflectable retention member (21) to prevent movement of the electrical contact (30) in the direction of the insert first face (11). The contact shoulder (311) is adapted to engage the insert shoulder (15) within the passage to prevent further movement of the contact in a direction away from the insert first face (11). The contact first shoulder (310) and second shoulder 311) captivates the electrical contact (30) in a predetermined position within the electrical connector insert (10).

The second enlarged portion (32) of the contact (30) includes an inwardly tapered portion that is tapered inwardly with respect to the axis of the insert passage in the direction of the insert first face (11). The tapered portion (320) of the second enlarged section (32) of a contact (30) provides a ramp which is adapted to slideably engage the inside wall of the removal bushing (40).

The removal bushing (40) is mounted around the end portion (36) of contact (30) and includes a radially extending flange (44) that facilitates the application of an axial force in either direction applied to the removal bushing (40). The forward portion (46) of the removal bushing (40) is generally comprised of a tubular member that is radially expandable. The removal bushing (40) is captivated on the contact (30) by the contact shoulder (38) and the enlarged portion (32) of the contact. An electrical conductor or a ferrule (60) for attaching an electrical conductor to the contact (30) is shown attached to the electrical contact (30).

FIG. 2 illustrates the contact removal bushing (40) in a position that has radially deflected the contact retention member (21) to allow movement of the contact (30) in the direction of the insert face (11). In this Figure, the contact (30) is shown in a partially withdrawn position wherein the first enlarged portion (31) is now disposed in a position that does not permit the retention members (21) to engage shoulder (310) and prevent withdrawal of the contact (30) from the passage bore.

FIG. 3 is a cross-sectional view of the contact and removal bushing taken along lines IIIIII of FIG. 2 which illustrates that the retention bushing (40) completely surrounds the electrical contact (30) except for an axial slot (41) which extends the entire length of the bushing (40). In thisembodiment the axial slot also extends through the radially extending flange (44).

FIG. 4 is a cross-sectional diagram of the bushing (40) shown in FIG. 3 which illustrates that the axial slot (41) extends the entire length of the bushing (40).

FIG. 5 illustrates an alternate embodiment of the bushing shown in FIG. 4. In this embodiment the axial slot (41) does not extend through the flange (44) at the end of the bushing (40).

FIG. 6 illustrates another embodiment of the removal bushing shown in FIG. 4. In this embodiment the end portion opposite the flange (44) includes a raised portion (43) in addition to the axial slot (41 This type of bushing would more commonly be used in the assembly illustrated in FIG. 1 where there is more clearance between the removal bushing (40) and the inner wall of the insert bore. This embodiment would expand radially further than the type of bushing shown in FIG. 4 because of the raised portion (43) at the end of the bushing. In this embodiment the bushing (40) need not necessarily include the axial slot (41), relying on the raised end portion (43) to deflect the retention members (21) that engage the contact shoulder (310).

OPERATION Referring now to FIGS. 1 and 2, the invention operates as follows: To remove a contact (30) from the insert (10) of an electrical connector, an axial force is applied to the flange (44) of removal bushing (40) in the direction of the contact shoulder (310). As can be seen in FIG. 2, the axial force moves the bushing (40) until it engages the tapered portion (320) of the enlarged section (32). The tapered portion (320) acts as a ramp for the inner wall of the bushing (40) to mount the enlarged portion (32) of the contact (30). In view of the fact that the bushing has an axial slot (FIG. 4) the bushing end portion that engages the enlarged portion (32) of the contact (30) expands radially. When the end portion of the removal bushing (40) expands radially it engages the contact retaining members (21) deflecting them outwardly so that they are disengaged from the contact shoulder (310). By applying a force to the ferrule or electrical conductor (60) in the direction of the arrow (FIG. 2) the contact (30) is moved in this direction a short distance. The contact removal bushing (40) is then moved in the same direction so that the end portion of the bushing disengages the enlarged portion (32) of the contact (30). The contact retaining members (21) will not be in a position to re-engage the shoulder (310) and prevent withdrawal. At'this point, application of an axial force to the flange (44) in the direction of the arrow will result the removal of the contact (30) from the insert It should be noted that in FIG. 1 the entrance passage (13) has a greater amount of clearance between the inner wall of the insert bore and the outside wall of the removal bushing (40) than shown in FIG. 2. Therefore, to remove the contact (30) shown in FIG. 2 a greater axial force would be required to install and remove the contact (30) in the connector insert (10).

While a preferred embodiment of the invention has been disclosed, it will be apparent to those skilled in the art that changes may be made to the invention as set forth in the appended claims and, in some instances, certain features of the invention may be used to advantage without corresponding use of other features. Accordingly, it is intended that the illustrative and descriptive materials herein be used to illustrate the principles of the invention and not to limit the scope thereof.

Havingdescribed my invention, what is claimed is:

1. In combination, a connector having an insert, a removable electrical contact, and an apparatus for releasing said contact from a bore in the connector insert, said contact having a first enlarged section forming a first shoulder and a second enlarged section adjacent said first shoulder, said contact secured in said bore by a radially deflectable and inwardly extending retention member that engages said first shoulder facing in the direction of said second enlarged section while the remaining portion of the contact that extends from said second enlarged portion in the direction away from said first shoulder is spaced from the surrounding walls of the bore, said second enlarged section further including a tapered portion which tapers radially inwardly in a direction away from said first shoulder, said apparatus comprising:

a bushing having a resiliently expandable end portion, said bushing slideably mounted on said contact portion that extends into said bore for axial movement of said expandable end portion into said bore so that when said bushing is forced over said second enlarged portion of said contact said bushing expands radially against said deflectable retention member whereby said inwardly extending retention member is radially deflected and disengaged from said contact first shoulder so that said contact may be withdrawn from said bore in said connector.

2. The combination recited in claim 1 wherein said bushing includes an axial slot from at least one end to permit said slotted end portion to be resiliently expandable.

3. The combination as recited in claim 1 wherein said bushing includes an axial slot along its entire length to permit one end portion to be radially expandable.

4. The combination as recited in claim 2 wherein said bushing includes stop means on at least a portion of said other end of said bushing for preventing said bushing from completely entering said bore.

5. The combination as recited in claim 3 wherein said bushing includes stop means on at least a portion of said other end of said bushing for preventing said bushing from completely entering said bore.

6. The combination recited in claim 5 wherein said stop means comprises an outwardly extending radial flange.

7. In combination with an electrical connector of the type having a plurality of removable contacts retained in the bores of the connector insert by radially deflectable and inwardly extending retention members which engage a first shoulder on said contact, said contact further including a second rounded shoulder adjacent said deflectable retention member, the improvement comprising:

a bushing mounted for axial movement on the portion of said contact having said second rounded shoulder, said bushing including a resiliently expandable end portion that engages said second .shoulder and expands radially to deflect said retention members and disengage them from contact with said first shoulder when said bushing is axially moved into engagement with said second shoulder, whereby said retaining members are disengaged from said first shoulder and said contact may be withdrawn'from said connector insert.

8. The apparatus as recited in'claim 7 wherein said bushing includes an axial slot along its entire length to permit said end portion to be resiliently expandable.

9. The apparatus recited in claim 7 wherein said second shoulder tapers inwardly to said remaining portion of said contact in the direction away from said first shoulder.

10. The apparatus recited in claim 8 wherein said second shoulder tapers inwardly to said remaining portion of said contact in the direction away from said first shoulder.

11. The apparatus as recited in claim 9 wherein said bushing includes an axial slot along its entire length to permit one end portion to be radially expandable.

12. The apparatus as recited in claim 7 wherein said bushing includes an axial slot from at least one end to permit said one end portion to be radially expandable.

13. The apparatus as recited in claim 9 wherein said bushing includes an axial slot from at least one end to permit said one end portion to be radially expandable.

14. The apparatus as recited in claim 12 wherein said bushing includes an outwardly extending radial flange in each of said bores, each of said retention members including at least one radially deflectable and inwardly extending retention finger adapted to engage a shoulder on a contact inserted therein, the improvement comprising:

a contact disposed in each of said bores and secured in place by said deflectable retention finger, each of said contacts having a first enlarged section forming a first shoulder and a second enlarged section adjacent to and spaced from said first shoulder, said contact secured in said bore by said radially deflectable retention finger that extends inwardly to engage said first shoulder on said contact, said second enlarged section disposed adjacent said first shoulder in the direction of said opening at said first face, said second enlarged contact section further including an inwardly tapered portion that extends from said second enlarged section to said remaining portion of said contact in the direction of said opening in said insert first face; and

bushing having a resiliently expandable end portion, said bushing slideably mounted on said contact portion that extends through said opening at said first face so that axial movement of said bushing allows movement of said expandable end portion into said bore, whereby when an axial force is applied to said bushing in the direction of said first contact shoulder, said bushing is forced over said second enlarged portion of said contact to expand said bushing resiliently expandable end portion which then deflects said retention fingers out of engagement with said contact first shoulder thereby enabling withdrawal of said contact. 

1. In combination, a connector having an insert, a removable electrical contact, and an apparatus for releasing said contact from a bore in the connector insert, said contact having a first enlarged section forming a first shoulder and a second enlarged section adjacent said first shoulder, said contact secured in said bore by a radially deflectable and inwardly extending retention member that engages said first shoulder facing in the direction of said second enlarged section while the remaining portion of the contact that extends from said second enlarged portion in the direction away from said first shoulder is spaced from the surrounding walls of the bore, said second enlarged section further including a tapered portion which tapers radially inwardly in a direction away from said first shoulder, said apparatus comprising: a bushing having a resiliently expandable end portion, said bushing slideably mounted on said contact portion that extends into said bore for axial movement of said expandable end portion into said bore so that when said bushing is forced over said second enlarged portion of said contact said bushing expands radially against said deflectable retention member whereby said inwardly extending retention member is radially deflected and disengaged from said contact first shoulder so that said contact may be withdrawn from said bore in said connector.
 2. The combination recited in claim 1 wherein said bushing includes an axial slot from at least one end to permit said slotted end portion to be resiliently expandable.
 3. The combination as recited in claim 1 wherein said bushing includes an axial slot along its entire length to permit one end portion to be radially expandable.
 4. The combination as recited in claim 2 wherein said bushing includes stop means on at least a portion of said other end of said bushing for preventing said bushing from completely entering said bore.
 5. The combination as recited in claim 3 wherein said bushing includes stop means on at least a portion of said other end of said bushing for preventing said bushing from completely entering said bore.
 6. The combination recited in claim 5 wherein said stop means comprises an outwardly extending radial flange.
 7. In combination with an electrical connector of the type having a plurality of removable contacts retained in the bores of the connector insert by radially deflectable and inwardly extending retention members which engage a first shoulder on said contact, said contact further including a second rounded shoulder adjacent said deflectable retention member, the improvement comprising: a bushing mounted for axial movement on the portion of said contact having said second rounded shoulder, said bushing including a resiliently expandable end portion that engages said second shoulder and expands radially to deflect said retention members and disengage them from contact with said first shoulder when said bushing is axially moved into engagement with said second shoulder, whereby said retaining members are disengaged from said first shoulder and said contact may be withdrawn from said connector insert.
 8. The apparatus as recited in claim 7 wherein said bushing includes an axial slot along its entire length to permit said end portion to be resiliently expandable.
 9. The apparatus recited in claim 7 wherein said second shoulder tapers inwardly to said remaining portion of said contact in the direction away from said first shoulder.
 10. The apparatus recited in claim 8 wherein said second shoulder tapers inwardly to said remaining portion of said contact in the direction away from said first shoulder.
 11. The apparatus as recited in claim 9 wherein said bushing includes an axial slot along its entire length to permit one end portion to be radially expandable.
 12. The apparatus as recited in claim 7 wherein said bushing includes an axial slot from at least one end to permit said one end portion to be radially expandable.
 13. The apparatus as recited in claim 9 wherein said bushing includes an axial slot from at least one end to permit said one end portion to be radially expandable.
 14. The apparatus as recited in claim 12 wherein said bushing includes an outwardly extending radial flange at said other end.
 15. The apparatus as recited in claim 13 wherein said bushing includes an outwardly extending radial flange at said other end.
 16. In combination with a multipin electrical connector having an insert that includes a first face, a second opposite face and a plurality of axially aligned bores through said insert from said first face to said second face and an opening at one face of said insert adapted to receive a contact, and a retention member disposed in each of said bores, each of said retention members including at least one radially deflectable and inwardly extending retention finger adapted to engage a shoulder on a contact inserted therein, the improvement comprising: a contact disposed in each of said bores and secured in place by said deflectable retention finger, each of said contacts having a first enlarged section forming a first shoulder and a second enlarged section adjacent to and spaced from said first shoulder, said contact secured in said bore by said radially deflectable retention finger that extends inwardly to engage said first shoulder on said contact, said second enlarged section disposed adjacent said first shoulder in the direction of said opening at said first face, said second enlarged contact section further including an inwardly tapered portion that extends from said second enlarged section to said remaining portion of said contact in the direction of said opening in said insert first face; and a bushing having a resiliently expandable end portion, said bushing slideably mounted on said contact portion that extends through said opening at said first face so that axial movement of said bushing allows movement of said expandable end portion into said bore, whereby when an axial force is applied to said bushing in the direction of said first contact shoulder, said bushing is forced over said second enlarged portion of said contact to expand said bushing resiliently expandable end portion which then deflects said retention fingers out of engagement with said contact first shoulder thereby enabling withdrawal of said contact. 